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Development of Real-time Information Management System(RIMS) to Continuous Galvanizing Line(CGL) at the Asan Bay Works, Dongbu Steel Co., Ltd. May 11-14, 2003 2003 OSIsoft Users Conference. Dongbu Steel Co., Ltd. www.dongbusteel.co.kr. Contents. Who are we? Motivation The Goal

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May 11 14 2003 2003 osisoft users conference

Development of Real-time Information Management System(RIMS) to Continuous Galvanizing Line(CGL) at the Asan Bay Works, Dongbu Steel Co., Ltd.

May 11-14, 2003

2003 OSIsoft Users Conference

Dongbu Steel Co., Ltd.

www.dongbusteel.co.kr


Contents

Contents

Who are we?

Motivation

The Goal

What is new?

The results

Developed applications : #1~#4


Products

Who are we?

Products

Cold Rolled

Galvanized

Prepainted

TP / TFS

Pipe

H Beam

CHQ Wire

P.E.B

CD Bar


Works offices

Who are we?

Headquarters

Works & Offices

Inchon Works

Pohang Works

Asan Bay Works


What does the cgl continuous galvanizing line make

Motivation

What does the CGL (Continuous Galvanizing Line) make?

By utilizing the “sacrifice anode effects” of zinc layer over steel

it gives steel the corrosion resistance capability

with lower production cost


For what and

Motivation

For what and ...?

  • Improvement of Quality

  • Low Production Cost

By What and How?


What we need

Motivation

What we need?

Data type

Large amount of real-time data

Unrestricted for operator,

maintenance and technical members

Application

Data reliability

Real-time monitoring

Challenge

On-line storage over 3 years

Storage

Intranet / Internet

Korean Language

Accessibility

In-house control

Analysis tools


Improving process capabilities

The Goal

Improving Process Capabilities

Zinc Coating

Post Treatment

Inspection

Pre Treatment

Heat Treatment

Coating

Weight

Mechanical

Property

Coating

Amount

Adherence

Grade


The legacy system

What is new?

The Legacy system

LEVEL 3

Coil Data, Production Result

LEVEL 2

RIMS

Server

LEVEL 1 (PLC, DCS)

Real-time Data

IRMS

SIEMENS

TOSHIBA

RIMS

User

Real-time measurement

Thickness Temp. Coating Current

Tension Pressure ...


Rims architecture

What is new?

RIMS Architecture


1 st stage development results

The results

1st Stage Development Results


Main task real time coil inspection

Main Task : Real-time Coil Inspection


Customers are expecting no defects

Main Task

Customers are expecting no-defects.

On every point,

what is the history?

Thickness, Pre-treatment,

Heat treatment, Bath temp.,

Coating amount,Roll force,

Elongation, Amount of oil etc.

?

?


May 11 14 2003 2003 osisoft users conference

SENSOR 1

SENSOR 2

SENSOR n

Sm

Sw

Ss

ts-a

product

tm-a

tw-a

ts-b

tm-b

tw-b

ts-c

ts-m


Main screen

Main Task : Results

Main Screen

Coil Length

Winding Length

Thickness

Coil Tracking

Width

Coil Information

Temperature

Tension


Entry

Main Task : Results

Entry


Inspection

Main Task : Results

Inspection

Speed

Upper Limit

Lower Limit

Data Searching

Thickness

re-scaling

1st product

2nd product

3rd product

Process Status

Temp.

Coating Weight

Width

Pin Hole


Web version

Main Task : Results

WEB version

Chart

Sheet


Appl 1 retrieval of operation data

Appl. #1 : Retrieval of Operation Data


May 11 14 2003 2003 osisoft users conference

Appl. #1 : Retrieval of CGL Operation Data

Menu

1

3

2

4


Export to excel

Appl. #1 : Retrieval of CGL Operation Data

Export to Excel


Appl 2 monitoring and daily report system line operation and quality related items

Appl. #2 : Monitoring and Daily Report System - Line Operation and Quality Related Items


Functions

Appl. #2 : On line monitoring and Daily Report System

for Line operation and Quality related items

Functions

Operation Criteria

Alarm

Measured

Value

Taking measures

Upper Limit

RDB

RTDB

관리하한선

Lower Limit

Time

Alarm

Report

. Daily report via e-mail

. At anytime


Daily report sample 1

Appl. #2 : On line monitoring and Daily Report System

for Line operation and Quality related items

Daily Report Sample #`1


Daily report sample 2

Appl. #2 : On line monitoring and Daily Report System

for Line operation and Quality related items

Daily Report Sample #2

Sheet

E-mail


Appl 3 analysis of measuring devices

Appl. #3 : Analysis of Measuring Devices


Main screen1

Appl. #3 : Analysis of Measuring Devices

Major Measuring Devices

* Thickness Gauge

* Furnace Thermometers

* Zinc Coating Weight

* Tension Meters

* Pin Hole Detector

Main Screen


Furnace temperature

Appl. #3 : Analysis of Measuring Devices

Furnace Temperature


Zinc coating weight

Appl. #3 : Analysis of Measuring Devices

Zinc Coating Weight


Tension

Appl. #3 : Analysis of Measuring Devices

Tension


Daily report sensor trouble

Appl. #3 : Analysis of Measuring Devices

Daily Report – Sensor Trouble


Logging

Appl. #3 : Analysis of Measuring Devices

Logging


Appl 4 analyzing zinc coating weight

Appl. #4 : Analyzing Zinc Coating Weight


Analysis system configuration

Appl. #4 : Analyzing Zinc Coating Weight`

Air Knife

Level 1 PLC

Level 2

RIMS

Coating

Weight

Gauge

. Quality Factor

. Set Points

Measured Value of Sensors

Stored value in RIMS

User

Lab. test results

Level 3

Analysis System Configuration


Data sources

Appl. #4 : Analyzing Zinc Coating Weight`

Data Sources

Air Knife

Coating Weight

Gauge

Laboratory Test Results


Analyzing flow

Appl. #4 : Analyzing Zinc Coating Weight`

Analyzing Flow

Daily

Data Gathering

Statistical

Analysis per Coil

Long-term

Data

Analysis

Yes

C/W OK?

Data Archiving

No

Analyzing

C/W in Rolling Direction

Analysis

Data

Feedback

Laboratory

Test Result

Tuning


Results

Appl. #4 : Analyzing Zinc Coating Weight`

Results


Questions

Questions


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